Method for Producing a Finished Part from a Blank

ABSTRACT

The invention proposes producing finished parts for a finished product from blanks in a fully automatic process, the blanks being removed from a warehouse and worked by way of automatically defined tools in working stations of a production line in a defined working sequence to form the finished parts.

REFERENCE TO RELATED APPLICATION

This application claims priority under 35 USC § 119 to European PatentApplication No. 19 155 985.5, filed on Feb. 7, 2019, the entire contentsof where are incorporated herein by reference.

TECHNICAL FIELD

The invention relates to a method for producing a finished part from ablank.

SUMMARY

An object of the invention is to produce the finished part fully, or inany case substantially, automatically.

According to the invention, properties of the finished part areinitially defined. This is carried out, for example, by selecting afinished product comprising the finished part. As a result of theselection of the finished product, the properties of the finished partsincluded therein are completely or partially known. Some of theproperties of the finished parts may be variable after the selection ofthe finished product and then still must be defined. Properties of thefinished product are, for example, the dimensions thereof, the materialthereof, and possibly a surface finish. The list is not exhaustive. Thedimensions of the finished part are normally known when the finishedproduct including the finished part is selected. The material of thefinished part can likewise be defined as a result of the selection ofthe finished product or can still be selected.

Based on the properties of the finished part, and in particular thedimensions thereof and the material thereof, a blank suitable forproducing the finished part is selected, for example, from inventory. Inparticular, an optimized selection from the inventory is made, which isto say a workpiece that can be worked to form the finished part withlittle scrap, or a larger stock item from which a blank can be cut,which can be worked to form the finished part with little scrap, whereinthe remainder of the stock item can be used, again with little scrap, asa new stock item for one or more blanks. Scrap is disposed of, and oneor more remnants of the stock item from which the blank is produced arereturned to the warehouse as new or modified inventory once the blankhas been cut therefrom.

Tools for producing the finished part from the blank are selected basedon the selected blank and the properties of the finished part, andworking steps, a working sequence, which is to say the succession of theworking steps used to consecutively work the blank to form the finishedpart, are defined, and working stations are selected, on, at or in(hereafter, simply, in) which the blank is consecutively worked untilthe finished part is formed. The selection and definition of the blank,the tools, the working steps and working sequence, and the workingstations are carried out automatically according to an algorithm by wayof a computer program.

The selection of the tools is dependent, among other things, on thematerial of the blank: for example, different tools are normally usedfor working wood or plastic material than are used for working stone ormetal, for example. The tools needed to produce the finished part fromthe blank must be selected from available tools. There may bealternative tools in place, from which a suitable tool or a combinationof suitable tools is selected. In addition, it must be taken intoconsideration which tools are available in which working station.

Interrelationships exist between the selection of the tools, thedefinition of the working steps and working sequence, and the definitionof the working stations into which the blank is consecutively introducedand worked, using the tools available there, until the finished part isformed: for example, the working steps and the working sequence dependon the available tools, wherein it must, in turn, be taken intoconsideration which tools are available in which working station. Themethod is, in particular, optimized to the effect that a workpiece isworked only once in a working station, if possible. Workpiece refers tothe blank and the blank that has been worked in the various workingstages until the finished part is formed. The workpiece may also bereferred to as an intermediate part in working stages between theunworked blank and the finished part. In a working station, theworkpiece can be worked simultaneously and/or consecutively by differenttools. In isolated cases, it is also possible to work the blank in asingle working station until the finished part is formed.

A working station can comprise one or more robots, which remove theparticular tool from a tool magazine, work the workpiece, andsubsequently return the tool to the tool magazine. A working station canalso comprise a machine tool, a paint spray booth, a welding station or,generally speaking, a joining station and/or a forming machine. The listis by way of example and not exhaustive.

For the working process, the workpiece is clamped in the workingstations, which shall be understood to mean a fixation of the workpieceagainst forces exerted on the workpiece by the working process. Oneembodiment of the invention provides that a position of the workpiece inthe particular working station is detected automatically. The workpieceis oriented in a target position for the working process and/or theworkpiece is worked as a function of the position thereof in the workingstation.

For example, the workpiece is clamped mechanically in the workingstations, such as by way of clamping jaws and/or clamping brackets or ina jaw chuck, magnetically, if the workpiece is made of a ferromagneticmaterial, and/or pneumatically using a vacuum chuck, and in particular avacuum table. The list of clamping devices and clamping options is byway of example and not exhaustive. The vacuum chuck generates a negativepressure, which is to say a pressure lower than an ambient pressure,between the workpiece and the clamping device, so that the ambientpressure presses the workpiece against the clamping device. Suctionopenings of the vacuum chuck can preferably be switched on and offindividually or in groups, and suction openings not covered by theworkpiece are preferably switched off.

After one, not necessarily after each, working step, properties of theworkpiece, and in particular dimensions, possibly the surface finish,are checked automatically, and the workpiece is reworked if the checkedproperties are outside a tolerance. Reworking can also be provided for alater working step, possibly in a different working station.

Wear of the selected and used tools is also preferably checkedautomatically. This is possible, for example, based on a working force,based on checking of the properties of the workpiece, and in particularof the dimensions, by measuring the temperature at the tool and/or at aspot of the workpiece being worked, or, for example, also based onconcentricity or vibrations of the tool during the working process. Worntools are replaced automatically. Until worn tools are replaced,according to one embodiment of the invention, the workpiece and/orsubsequent workpieces are worked using substitute tools, which areselected from the available tools and which allow the finished part tobe produced or completed.

According to a preferred embodiment of the invention, a customer, forexample, selects a finished product on a mobile computer, in particularon a smart phone or a tablet computer, which comprises one or morefinished parts that can be produced by the method according to theinvention. The mobile computer makes finished products comprising one ormore finished parts that, as mentioned, can be produced by the methodaccording to the invention, available in a virtual manner. The finishedproduct can comprise further components, such as purchased parts orparts produced in another manner. The finished part or parts producibleby the method according to the invention are produced according to theinvention.

According to one refinement, a space, such as a room, is detected by wayof the mobile computer, and the selected finished product is displayedin the space, on a screen of the computer. Dimensions of the space,windows and doors, wall colors and the like are detected. The customeris able to view the finished product in the space on the screen of thecomputer, preferably from different directions. He or she can select,change and adapt surfaces, materials, colors and dimensions. In thisway, the properties of the finished part are defined, based on which theblank, the working steps, the tools and the like are automaticallyselected according to an algorithm or by way of a computer program.Following the detection of the space, it is also possible toautomatically check whether the selected finished product fits alocation in the space selected by the customer, in terms of the shape,size, and possibly the weight. If necessary, adaptations, such asrecesses, can be provided on the finished product, which must be carriedout on the workpiece or workpieces. According to the invention, this isalso carried out automatically by way of the algorithm or the computerprogram.

All of the features mentioned in the description and/or shown in thedrawing can be implemented individually alone or in any arbitrarycombination in embodiments of the invention. Embodiments of theinvention that do not comprise all, but only some of the features of aclaim, or of the independent claim, are possible.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will be described hereafter based on a mobile computer,and reference is made to the drawings in which:

FIG. 1 shows a mobile computer;

FIGS. 2 to 4 illustrate two production lines; and

FIGS. 5A-5C show a program flow chart

DETAILED DESCRIPTION

In particular, FIGS. 1 to 4 are simplified representations.

The invention is used to produce finished parts from blanks in a fullyautomatic process. Working stages of the blanks between the unworkedblanks and the finished parts are also referred to here as intermediateparts, and the blanks, intermediate parts and finished parts are alsoreferred to as workpieces. The goal of the invention is the fullyautomatic, or in any case substantially automatic, production offinished parts for a finished product comprising the finished parts. Thefinished product can also only be composed of one finished part or cancomprise further finished parts that are produced in another manner, orare purchased.

At the beginning of the method according to the invention, properties ofthe finished part or parts to be produced are defined. Such propertiesare, in particular, dimensions and/or geometry and material, ormaterials, of the finished part or parts. Additional properties may bethe color and structure of surfaces of the finished parts.

So as to define the properties of the finished parts, one embodiment ofthe invention provides that a finished product is selected by way of amobile computer 1, such as a laptop, a tablet computer or a smart phone.The mobile computer 1 includes, or has access to, a database including aselection of finished products. The finished part or parts to beproduced, and the properties thereof, are defined by the selectedfinished product.

A preferred variant of the method according to the invention providesmeasuring a space in which the selected finished product is to bedisposed, by way of the mobile computer 1. For example, the space is aroom in a building. So as to measure the space, the space is recorded,in particular, by way of a camera of the mobile computer 1 usingdifferent viewing directions, as is schematically shown in FIG. 1 on thebottom right of sheet 6/6 illustrating a corner 20. The recordings canbe photos and/or videos. The recordings must be calibrated, for whichpurpose distances with respect to corners of the space are measured, forexample, and entered into a computer program, for example an app storedon the mobile computer 1. The computer program preferably specifieswhich distances must be measured based on the recorded photos and/orvideos. The selected finished product can now be displayed in the space,on a screen of the mobile computer 1. It is still possible, at thispoint, to modify the finished product, and in particular the dimensions,materials and surfaces thereof, or another finished product can beselected. The computer program checks whether the selected finishedproduct fits the space. Another option is to make changes to thefinished product or on the finished parts included therein. For example,it is possible to provide openings and recesses for cables, receptaclesor protrusions projecting into the space on the finished parts to beproduced.

The properties of the finished part or parts to be produced can also bedefined differently, such as by way of manual input.

The finished parts are produced by way of a production line 2, forexample, such as is shown in FIG. 2. Blanks 3 are removed from awarehouse, which is not shown, for example from a fully automatichigh-bay racking system, and, for example, are transported to theproduction line 2 by a self-propelled industrial truck, which is notshown. At one end, a first robot 4 consecutively places the blanks 3onto a roller conveyor 5 of the production line 2. The roller conveyor 5can, generally speaking, also be understood to be a conveyor system.

The roller conveyor 5 conveys the blanks 3 to working stations 6disposed consecutively on the roller conveyor 5 in a conveyingdirection. In the exemplary embodiment, the production line 2 comprisestwo working stations 6, each comprising two robots 7 disposed oppositeone another on the two sides of the roller conveyor 5. A tool magazine 8from which a robot may remove tools for working the blanks 3 is assignedto each robot 7. As a result of the working process, the blanks 3 becomeintermediate parts 9, as mentioned above, and the finished parts 10 atthe end of the working process. The blanks 3, intermediate parts 9 andfinished parts 10 can also be understood to be workpieces 11.

Each working station 6 comprises a clamping device 12 for fixing theworkpieces 11 during the working process. The working stations 6 can,for example, comprise mechanical clamping devices including, forexample, clamping jaws and/or clamping brackets, electromagneticclamping devices for ferromagnetic workpieces or, as shown in theexemplary embodiment, a vacuum table 13 as a clamping device 12.

After having been worked in the working stations 6 to form the finishedpart 10, the blank 3 is conveyed by the roller conveyor 5 to an endlocated opposite the end at which the blank 3 was placed onto the rollerconveyor 5 by the first robot 4, where a final robot 14 removes thefinished parts 10 from the roller conveyor 5 and, for example, stacksthese for shipping.

FIGS. 3 and 4 show an alternative production line 2 comprising machinetools 15 at the working stations 6. FIGS. 3 and 4 also show gantrymachine tools 15. A combination of robots 7 and machine tools 15 is alsopossible. The production line 2 can also comprise one or more joiningstations, such as welding stations, soldering stations and/or bondingstations, forming stations, paint spray booths or painting stationsand/or laminating stations (not shown). The list is by way of exampleand not exhaustive.

Based on the properties of the finished part or parts to be produced,the method according to the invention, which may be implemented as acomputer program, for example, selects one or more blanks suitable, interms of shape, size and material, for producing the finished parts frominventory, for which purpose the computer program has access to adatabase including the inventory of blanks, which is updated by thecomputer program. The method according to the invention is shown in theform of a flow chart or workflow in FIGS. 5A-5C. For the production ofthe finished part 10, a stock item is selected, from which the blank 3or the finished part 10 can be produced with as little scrap aspossible. A remainder or remainders of the stock item that can be usedfor further, even different, finished parts is or are returned to thewarehouse, and the inventory in the database is updated. Scrap isdisposed of.

Moreover, the method according to the invention for producing thefinished part offers suitable tools and defines working steps, a workingsequence and working stations in which the working steps are carriedout. A working step involves working a workpiece by way of a tool.Alternative tools for producing the finished part can be present, fromwhich the method selects those by which the finished product can beproduced. The selections of the tools, working steps, working sequenceand working stations are dependent on one another and on the blank, andin particular on the material thereof. In addition, the selections anddefinitions are influenced by which tools are available in which workingstation. The tools, working steps and working sequence are preferablydefined so that the workpieces can be transferred consecutively from apreceding working station to a subsequent working station and reach orenter a working station only once, to the extent possible. In eachworking station, one or more working steps can be carried out by way ofone or more tools. For the selection of the tools and the definition ofthe working steps, working sequence and working stations, the methodaccording to the invention or the underlying computer program has accessto one or more tool databases in which the tools available at theworking stations or, generally speaking, also the working steps possiblein the working stations, are stored.

The selected blank is removed from the warehouse, preferablyautomatically, and transported to the production line or a (first)working station. The database encompassing the inventory of blanks isupdated. In the working station, a position of the blank, which can alsobe understood to be a workpiece, is determined automatically and/or theblank is oriented into an intended position and fixed. If a clampingdevice for clamping the workpiece during the working process comprises asuction device, such as a vacuum table, suction openings that arecovered by the workpiece are switched on, and suction openings outsidethe workpiece are switched off, if possible.

While the position of the workpiece in the working station is beingdetermined and the workpiece is being oriented and clamped, a robot, amachine tool or the like of the working station removes a first, definedtool from the associated tool magazine and clamps it. Afterwards, theworkpiece is worked by way of the tool, which is referred to as aworking step. Working may be, for example, machining, non-machining,forming and/or joining working processes. The list is by way of exampleand not exhaustive. A workpiece may also be worked simultaneously by wayof multiple tools in a working station.

After working, which is to say after a working step, the workpiece canbe checked for dimensional accuracy, surface quality and the like.Reworking of the workpiece may possibly be carried out in the sameworking station using the same tool. Reworking of the workpiece can alsobe provided to be carried out by way of a tool used at a later pointand/or in a downstream working station.

Prior to, during or after working of the workpiece, the respective usedtool can be checked for wear. The check for wear is preferably carriedout automatically. It is also possible to check the tools in the toolmagazine for wear, in particular after one or more uses of a tool. Acheck for wear can be done visually, for example, and/or a wearmeasurement is carried out. As the workpiece is being worked, a feedforce or a driving torque of the workpiece and/or a temperature at aspot being worked can be measured. If the measured values are higherthan expected, this is an indication of wear of the tool. Worn tools inthe tool magazine are replaced. Until a worn tool is replaced, themethod according to the invention can select an alternative tool, orpossibly also multiple alternative tools, which are available in theworking station or a downstream working station and by which thefinished part can be produced.

Once the working process of the workpiece by way of the tool iscompleted, the tool is automatically returned into the tool magazine,and a tool defined for a subsequent working step is removed from thetool magazine, by way of which the workpiece is subsequently workedfurther in the working station.

When the working process for the workpiece in the working station iscomplete, the workpiece is transported to the defined subsequent workingstation, where it is worked by way of the defined tools in theabove-described manner.

When the workpiece is finished, which is to say the finished part hasbeen produced, it is removed from the (final) working station or fromthe production line, preferably automatically, such as by a robot.Preferably, all the finished parts assigned to a finished product arearranged and made available, for example stacked, for packaging andshipping.

1. A method for producing a finished part from a blank, whereinproperties of the finished part are defined, a blank suitable forproducing the finished part is selected, tools suitable for producingthe finished part from the selected blank are selected, working stepsand a working sequence suitable for producing the finished part aredefined, and working stations suitable for producing the finished partfrom the blank are selected.
 2. The method according to claim 1, whereinthe working steps and the working sequence suitable for producing thefinished part from the selected blank are defined, taking the selectedtools into consideration, and/or the working stations suitable forproducing the finished part from the blank are selected, taking theselected tools, the working steps and the working sequence intoconsideration.
 3. The method according to claim 1, wherein the selectedblank is transported to a working station, or consecutively to aplurality of working stations, clamped and worked to form the finishedpart or to form an intermediate part, which is transported to asubsequent working station, clamped and worked further to form anintermediate part, until the finished part has been produced in a finalworking station.
 4. The method according to claim 3, wherein a positionof the blank or of the intermediate part in the working station isdefined, possibly the blank or the intermediate part is oriented, andthe blank or the intermediate part is worked as a function of theposition thereof in the working station.
 5. The method according toclaim 1, wherein the working station comprises a vacuum chuck forclamping the blank or the intermediate part.
 6. The method according toclaim 5, wherein the vacuum chuck includes a plurality of suctionopenings, and suction openings that are not covered by the blank or theintermediate part are switched off.
 7. The method according to claim 1,wherein, subsequent to a working process in a working station,properties of the intermediate part or of the finished part are checkedautomatically, and the intermediate part or the finished part isreworked, if necessary.
 8. The method according to claim 1, whereinselected tools are checked automatically for wear, and worn tools areautomatically replaced.
 9. The method according to claim 8, whereinsubstitute tools are automatically selected from available tools forworn tools until the worn tools have been replaced.
 10. The methodaccording to claim 1, wherein a finished product comprising one or morefinished parts that are produced by the method is selected on a mobilecomputer.
 11. The method according to claim 10, wherein a space isdetected by way of the mobile computer, and the finished product isdisplayed in the space.